Form No. 3354-310 Rev B Z500 Z Master, With 52in or 60in 7-Gauge Side Discharge Mower Model No. 74248—Serial No. 260000001 and Up Model No. 74249—Serial No. 260000001 and Up Register your product at www.Toro.
Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. Figure 1 1.
Using the Rollover Protection System (ROPS).................. 16 Think Safety First .............................. 17 Operating the Parking Brake .............. 18 Starting and Stopping the Engine .............................. 18 Operating the Power Take Off (PTO) ............................... 20 The Safety Interlock System............... 20 Driving Forward or Backward ............ 21 Stopping the Machine ........................ 22 Adjusting the Height-of-Cut ..............
Safety hair, loose clothing or jewelry may get tangled in moving parts. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-“personal safety instruction." Failure to comply with the instruction may result in personal injury or death.
• Keep hands and feet away from the cutting units. • Never carry passengers and keep pets and bystanders away. • Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. • Slow down and use caution when crossing roads and sidewalks. Stop blades if not mowing. • Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the mower under the influence of alcohol or drugs.
• Carefully release pressure from components with stored energy. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
Slope Chart 7
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 107-2112 106-9969 108-5278 1. Read the Operator’s Manual.
8-4387 1. Warning—wear hearing protection.
7-3069 1. Warning—there is no rollover protection when the roll bar is down. 2. To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt. Lower the roll bar only when absolutely necessary; do not wear the seat belt when the roll bar is down. 3. Read the Operator’s Manual; drive slowly and carefully.
104-8569 66-1340 98-5954 105-7798 1-403005 68-8340 107-1687 107-1613 58-6520 1.
1-633462 1-643339 103-5881 107-9309 1. Warning—read the Operator’s Manual for information on charging the battery; contains lead; do not discard. 2. Read the Operator’s Manual. Manufacturer’s Mark 1. Indicates the blade is identied as a part from the original machine manufacturer. Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. 5.
106-7492 106-9989 107-8076 1. Fast 2. Slow 3. Neutral 13 4.
Product Overview Controls Become familiar with all the controls before you start the engine and operate the machine (Figure 3 and Figure 4). Figure 4 1. Ignition switch 2. Throttle 3. Choke Figure 3 1. 2. 3. 4. Motion control lever Parking brake lever Height-of-cut lever Fuel cap (both sides) 5. 6. 7. Controls Seat belt Roll bar 4. 5. 6. Power take off (PTO) Hour meter Gas cap Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running.
Operation In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel • Always place gasoline containers on the ground away from your vehicle before filling. Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum).
• Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting There is no rollover protection when the roll bar is in the down position. Important: Do not use fuel additives containing methanol or ethanol. • Lower the roll bar only when absolutely necessary. Add the correct amount of gas stabilizer/conditioner to the gas. • Do not wear the seat belt when the roll bar is in the down position.
Think Safety First 5. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 6). 6. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 6). Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Important: Always use the seat belt with the roll bar in the raised position.
Setting the Parking Brake 1. Move the motion control levers (Figure 16) out to the neutral lock position. 2. Pull up and back on the parking brake lever to set the parking brake (Figure 10). The parking brake lever should stay firmly in the engaged position. Parking brake may not hold machine parked on a slope and could cause personal injury or property damage. Do not park on slopes unless wheels are chocked or blocked Figure 8 1. Safe Zone-use the Z Master 3.
3. Move the PTO (power take off) switch to the Off position (Figure 11). Figure 13 Figure 11 1. PTO—on 2. 1. PTO—off Throttle—fast 2. Throttle—slow 6. Turn the ignition key to Start (Figure 14). When the engines starts, release the key. 4. Move the choke control to the on position before starting a cold engine (Figure 12). Important: Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 30 second cool-down period between attempts.
4. Turn the ignition key to the off position and remove the key (Figure 14). 5. Close the fuel shut off valve before transporting or storing the machine. Refer to Fuel System Maintenance, page 33. Important: Make sure that the fuel shut off valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge. Figure 15 1.
engaged or if you rise from the seat when the PTO is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. Testing the Safety Interlock System Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. • Use caution when making turns. • Slow the machine down before making sharp turns.
Driving Backward 1. Move the levers to the center, un-locked position. 2. To go backward, slowly pull the motion control levers rearward (Figure 16). To go straight, apply equal pressure to both motion control levers (Figure 16). To turn, release pressure on the motion control lever toward the direction you want to turn (Figure 16). To stop, push the motion control levers to the neutral position. Figure 17 1. Height of cut lever 2. Clevis Pin Stopping the Machine 2.
Figure 19 1. 2. 3. Figure 18 1. Outer roller 2. Spacer 3. Bushing 4. 5. Bolt Nut Outer roller Spacer Bushing 4. 5. Bolt Nut 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Figure 19). 4. Select a hole so that the outer roller is positioned to the nearest corresponding height-of-cut desired (Figure 18). Note: Do not adjust the rollers to support the mower housing. 5. Install the outer roller, bushing, spacer, bolt, and nut (Figure 18).
to neutral locked position and apply parking brake. Remove the key. 2. Rotate the by-pass valves counterclockwise 1 turn to push. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Figure 22). Important: Do not rotate by-pass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out. Figure 20 1. Adjustment lever Unlatching the Seat Push the seat latch rearward to unlatch the seat.
Important: Do not use the motion control levers as anchors for tieing the machine down. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Secure a trailer to the towing vehicle with safety chains.
Operating Tips Fast Throttle Setting Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. For best mowing and maximum air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.
Long Grass If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. When Stopping If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 8 operating hours • Change the engine oil. • Check the hydraulic uid. • Change the hydraulic lter. Before each use or daily • • • • Check the safety interlock system. Check the engine oil. Check the mower blades. Clean the mower deck. Every 25 hours • Clean the foam air cleaner element (more often in duty or sandy conditions). • Check the hydraulic uid.
How to Grease 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease.
Figure 26 1. Knob 2. Air cleaner cover 3. Air cleaner nut 4. 5. Paper element Foam element Figure 25 4. Carefully slide the foam element off the paper element (Figure 26). 4. Grease the idler pulley pivot (Fig. 38). 5. Unscrew the cover nut and remove the paper element (Figure 26). Engine Maintenance Cleaning the Foam Element 1. Wash the foam element in liquid soap and warm water (Figure 27). When the element is clean, rinse it thoroughly.
Figure 28 1. Paper element 2. Figure 29 Rubber seal 2. Inspect the element for tears, an oily film, and damage to the rubber seal. Checking the Engine Oil Level Important: Never clean the paper element with pressurized air or liquids. Replace the paper element if it is damaged, or cannot be cleaned thoroughly. Note: Check the oil when the engine is cold. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
enough oil into the filler tube to raise the level to the full mark. 9. Slowly pour approximately 80% of the specified oil into the filler tube (). 10. Check the oil level; refer to Checking the Engine Oil Level. 11. Slowly add the additional oil to bring it to the Full mark. Important: Do not overfill the crankcase with oil because the engine may be damaged. Do not run engine with oil below the low mark because the engine may be damaged. Changing the Engine Oil Filter Changing the Oil 1.
and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. • Type: NGK[ BPR4ES or equivalent • Air Gap: 0.030 inch (0.75 mm) Removing the Spark Plug Figure 34 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1. 2. Canter electrode insulator Side electrode 3.
3. Close fuel shut-off valve (Figure 36). Figure 35 1. Filter 2. Fuel shut-off valve 3. Hose clamp Figure 36 1. Filter 2. Fuel shut-off valve 5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 35). 6. Remove the filter from the fuel lines. 7. Install a new filter and move the hose clamps close to the filter to secure the fuel line (Figure 35). 8. Wipe up any spilled fuel. 9. Open the fuel shut-off valve. 3. Hose clamp 4.
5. Slide the red terminal boot off the positive (red) battery terminal. Then remove the positive (red) battery cable (Figure 37). Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands. Removing the Battery Battery terminals or metal tools could short against metal machine components causing sparks.
Charging the Battery The fuses are as follows: • Main F1-30 amp, blade-type • Alternator F2-25 amp, blade-type Charging the battery produces gasses that can explode. 1. Unlatch the seat and raise the seat to gain access to fuse holder (Figure 39). Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1.
Drive System Maintenance Checking the Tire Pressure Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 41). Adjusting the Tracking Maintain the air pressure in the front and rear tires at 13 psi (90 kPa). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading. Note: Determine the left and right sides of the machine from the normal operating position.
Figure 42 1. Slotted Nut 2. Two threads or less showing 3. 4. Hole in threaded shaft Washer (if needed) 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 42). 6. If more than two threads are showing remove nut and install washer between hub and nut. Figure 43 7. Torque the slotted nut to 125 ft-lb. (170 N⋅m) (Figure 42). 1. Spring Washers 2. Lock Nut 8.
Figure 44 1. Oil cooler Figure 46 1. 2. Cleaning the Engine Fins 3. Every 100 hours clean the engine cylinder and cylinder head cooling fins. Also clean around carburetor, governor levers and linkage. This will make sure adequate cooling to hydraulic pumps, motors and engine and will reduce the possibility of overheating and mechanical damage. Brake lever Spring (2-3/4 inches/70 mm) Adjusting nuts 4. 5. Collar on brake rod 3/16–1/4 inch (5–7 mm) 6. Jam nut and yoke 3.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the belt covers over the outside spindles. 4. Loosen the fixed idler arm and adjust it to relieve the belt tension on the fixed idler pulley (Figure 47). Figure 47 1. 2. Fixed idler arm Square hole 3. Fixed idler pulley 4. Mower belt 5. Belt guide 6. Spring-loaded idler pulley 5. Remove the old belt. 6. Install the new belt through the belt guide and on the pulleys (Figure 47). 7.
Figure 49 2. Install new belt around engine and hydro pump pulleys (Figure 49). Figure 50 1. 2. 3. Pull spring loaded idler down and align below traction belt. Release the pressure on the spring loaded idler (Figure 49). Neutral locked position Control lever 3. Neutral position 6. Pull the lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Figure 50). Controls System Maintenance 7.
Disposing the Mercury Tilt Switch Several states have passed laws concerning the disposal of devices containing mercury. In all the remaining states it is advisable to follow similar procedures. The laws state that these sealed devices contain mercury and should not be placed in the garbage until the mercury is removed and reused, recycled or otherwise managed to insure that it does not become part of solid waste or waters.
Note: There are two ways of checking the hydraulic oil. One is when the oil is warm and one is when the oil is cold. The baffle inside the tank has two levels depending if the oil is warm or cold. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 1. Position the machine on a level surface and set the parking brake. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury.
Bleeding the Hydraulic System The traction system is self bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system. 1. Raise rear of the machine so wheels are off the ground and support with jack stands. Figure 53 2. Start the engine and run at low idle speed. Engage the lever and traction on one side and spin the wheel by hand. 1. Hydraulic lter 4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Figure 54). 3.
This adjustment must be made with drive wheels turning. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 1. Raise the frame and use jack stands to hold up the machine so drive wheels can rotate freely. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done. 2.
Figure 55 1. Tracking knob 2. Pump rod 3. 4. Adjustment bolt Yoke Figure 56 1. 2. 3. 4. 5. 6. 3. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. 4. Open the throttle to fast. Make sure wheel remains stopped or slightly creeps in reverse, adjust if necessary. Clevis pin in slot Nut against yoke Adjustment bolt Pump rod Double nuts Jam nut 7. 8. 9. 10. 11. Spring Pivot shaft Yoke Locknut Ball joint 2.
Electrical system will not perform proper safety shut off with jumper wire installed. • If one rear chain is loose, lower (loosen) the front support arm on the same side. Refer to Adjusting the Front-to-Rear Mower Pitch. • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed. • If one front chain is loose, raise (tighten) the front support arm for that chain. Refer to Adjusting the Front-to-Rear Mower Pitch.
Figure 58 1. 2. 3. 4. Rear chain Rear support arm Bolt Jam Nut 5. 6. 7. Figure 59 Adjustment bolt Front swivel Front support arm 1. Measure here from blade to hard surface 8. Loosen the jam nut under the rear support arm and adjust the adjustment bolt to get a measurement of 3-1/8 to 3-1/4 inches (Figure 58). 2. Measure at A and B 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 59). 3. Record this measurement.
Adjusting the Compression Spring damaged or worn, replace it immediately with a genuine Toro replacement blade. For convenient sharpening and replacement, you may want to keep extra blades on hand. 1. Raise the mower lift lever to the transport position. 2. Check the distance between the two large washers, it needs to be 11-1/8 inches (28.2 cm) for 52 inch mower decks and 10-1/2 inches (26.7 cm) for 60 inch mower decks (Figure 60).
2. Rotate the opposite ends of the blades forward. 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades. Figure 61 1. Cutting Edge 2. Curved Area 3.
Sharpening the Blades When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 63). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. Figure 65 1. 2. 3. Sail Area of Blade Blade Spring Disk 4. 5. Blade Bolt Cone Towards Bolt Head 3.
Figure 66 1. Bolt 2. Spacer 3. Locknut 5. 6. 7. 4. Spring 8. Spring installed Grass Deector Place behind deck edge before installing bolt Hook end of spring 2. Remove the damaged or worn grass deflector. 3. Install the bolt and nut. 4. Place the J hook end of the spring around the grass deflector (Figure 66). Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position.
Storage stabilizer manufacture. Do not use an alcohol based stabilizer (ethanol or methanol). 1. Disengage the power take off (PTO), set the parking brake and turn the ignition key to off. Remove spark plug wire. Remove the key. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
Troubleshooting Problem Starter does not crank Possible Cause Corrective Action 1. Blade control (PTO) is engaged. 2. Parking brake is not on. 3. Operator is not seated. 4. Battery is dead. 5. Electrical connections are corroded or loose. 1. Move blade contro (PTO) to disengaged. 2. Set the parking brake. 3. Sit on the seat. 4. Charge the battery. 5. Check the electrical connections for good contact. 6. Replace fuse. 7. Contact an Authorized Service Dealer. 6. Fuse is blown. 7.
Problem Machine does not drive. Abnormal vibration. Possible Cause 1. By pass valve is not closed tight. 2. Drive or pump belt is worn, loose or broken. 3. Drive or pump belt is off a pulley. 4. Broken or missing idler spring. 5. Hydraulic uid level is low or too hot. 1. Tighten the by pass valve. 2. Change the belt. 1. Cutting blade(s) is/are bent or unbalanced. 2. Blade mounting bolt is loose. 3. Engine mounting bolts are loose. 4. Loose engine pulley, idler pulley, or blade pulley. 5.
Problem Blades do not rotate. Possible Cause 1. Drive belt is worn, loose or broken. 2. Drive belt is off pulley. 3. Deck belt is worn, loose or broken. 4. Deck belt is off pulley. 5. Broken or missing idler spring. 56 Corrective Action 1. Check the belt tension. 2. Install drive belt and check adjusting shafts and belt guides for correct position. 3. Install new deck belt. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Replace the spring.
Schematics Wire Diagram (Rev.
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.
